KALIMPACT is a hard material hard material rubber composite. Depending on the specific abrasion and impact resistance requirements, KALIMPACT comprises either ABRESIST fused cast basalt, KALOCER oxide ceramics or with KALMETALL hard overlay welded plates. Each of the different material variations is formed into a vulcanised composite rubber sheet.
At a continuous casting plant steel ingots are cast and then cut to appropriate length. Due to the high temperatures, scale develops on the outside of the ingots and is rinsed away in chutes with water to a basin. The scale takes the form of grains some 5 mm in size and causes serious wear in the chutes. Nowadays it has become a standard throughout the world to line such chutes with ABRESIST fused basalt. The smooth surface reduces any deposition of material during transport, as well as protecting against abrasion wear.
Danieli is a global provider of iron and steel making technology. An important application is the transforming process from iron ore to direct reduced iron (DRI) which is done in the DRI reactor. In the DRI reactor one of the more sensitive parameters for maintaining product quality and performance is the discharge temperature of the pellets used to feed the electric arc furnace (EAF). Likewise, for feeding pellets to the hot briquetted iron (HBI) machine. The higher the temperature, the better will be HBI quality.
Our customer extracts and processes approximately 150 thousand tonnes per year of zinc and lead ores from their own mine. Zinc alloys are used in the smelting and automotive industries as well as for the continuous zinc-plating of products in the processing industry. In the course of refining, zinc oxide (ZnO) is conveyed at 400°C via pneumatic pipes and pipe bends from the sphalerite roasting plant to the leaching unit.
Upon delivery to sugar factories, beets are transported by conveyor belts or water flumes to the beet washing unit, where sand, leaves and stones are removed. The flume conveyor portion of this application is primarily subject to impact wear, while the rest of the application is subject to high abrasive wear.
In the preparation of iron ore, contaminated surface water travels at high velocity through channels to collection basins. The sharp-edged iron ore is highly abrasive to the concrete surfaces there. Frequent repairs are required as a result. Kalenborn lined the floor of the channels with smooth, wear-resistant ABRESIST fused cast basalt moulded elements. Wear-resistant KALCRET ANX hardening compound was selected to protect the less exposed walls. The combination lining has significantly extended service life and eliminated unscheduled repairs.
The cascade chute is a fail-safe means of conveying materials located at the top of a blast furnace. Raw materials, including heavy hot briquetted iron (HBI), are deposited onto the chute via the transport and conveyance systems to which it is connected. Such materials cause a great deal of abrasion and impact wear.
Kalenborn Abresist lined piping has many uses in the energy industry, handling abrasive solid fuels such as coal, petroleum coke or wood and the waste materials from the burning of these materials. The waste materials include bottom ash, fly ash, economizer ash, pyrites, sand and scrubber sludge.